Simulation and experimental study on surface residual stress of ultra-precision turned 2024 aluminum alloy

In order to reveal the influence of cutting parameters on the surface residual stress of 2024 aluminum alloy in ultra-precision cutting, the thermal coupling simulation of 2024 aluminum alloy ultra-precision cutting process was carried out based on ABAQUS software, and it was verified by the residual stress test of ultra-precision machined samples. The results show that the dominant factor of the machining residual stress of 2024 aluminum alloy ultra-precision with single crystal diamond tool is the plastic deformation caused by cutting force. With the normal ultra-precision machining parameters, the residual stress of the machined surface of 2024 aluminum alloy is mainly compressive stress. With the increase in distance to the machined surface, the residual compressive stress value decreases and gradually transforms into tensile stress, and the total residual stress depth is less than 8 mu m. With the increase in cutting depth (0.01-0.03 mm), the reduction of cutting speed (150-50 m/min) and the increase of feed (0.01-0.024 mm/r), there is an increasing trend of the residual stress on the machined surface of 2024 aluminum alloy workpiece, and the influences of feed rate and cutting depth on residual stress are slightly greater than that of cutting speed.